Power distribution system

ABSTRACT

A power distribution system is provided for an automobile mirror assembly or the like, and includes a flexible membrane having electrical traces electrically connected to the vehicle electrical system, and connecting sites for electrically connecting to various power consumers in the mirror assembly.

CROSS-REFERENCE TO RELATED APPLICATAION

[0001] This application claims benefit to U.S. provisional applicationSerial No. 60/309,011, filed on Jul. 31, 2001.

FIELD OF THE INVENTION

[0002] The present invention relates to electrical systems inautomobiles and the like, and, more particularly, to remote parts of theelectrical system such as the multi-function electrical system in anelectrically powered or electrically operated mirror, and the manner ofdistributing electrical power for the operation of each such function.

BACKGROUND OF THE INVENTION

[0003] In known automobile electrical systems, complicated wiringharnesses are routed throughout the automobile, to provide power for theever-increasing number of electrical functions. The trend in theindustry is to add additional safety and convenience features to theautomobile, many of which require electric power input.

[0004] Within even relative small features of an automobile, electricalsystem requirements can be complicated. For example, in exterior mirrorsof some car designs, as many as thirteen individual wires can berequired for the multiple functions associated with the new electronicmirrors. Common mirror functions, and the operators therefor functioningas electric consumers, include: mirror position adjustment with motorpacks, electronic dimming of reflected light from lights of vehicles tothe rear by the use of electrochromic cells, turn signal indicators inthe mirror housing, memory functions for mirror positioning of multipledrivers, mirror tilt down for reverse transmission gearing, mirrorheaters/defrosters, antennas, power folding of the mirrors particularlyon European models, and the like.

[0005] In known electrical systems for multifunction exterior mirrors,actuators and/or controllers are positioned within the automobile doors,and a wiring harness is routed through the door into the mirror housing.Individual wires from the wire harness are routed throughout the mirrorstructure to the various electrical consumers associated with each ofthe functions. With numerous individual wires in the harnesses, multipleconnectors are required, and the procedures for making the connectionsduring assembly of the mirror are complicated and time consuming toperform. As more and more mirror functions are built into the mirrors,more and more connectors are required, increasing the possibility of aconnector failure. Routing each wire properly, to avoid interferencewith physically moving components of the mirror, becomes more and morechallenging for designers. Designers are faced with the difficulty ofincorporating new and changing features with limitations on space andpower availability.

[0006] It is desirable to reduce weight wherever possible in automotivedesigns, for the added benefits of fuel economy. Reduction in the use ofwires, connectors, solder and materials and processes known to havedetrimental environmental effects is also striven for. Many of thesegoals have been contradictory, such as increasing electrical convenienceand safety functions, while reducing the use of wires, connectors andsolder.

[0007] Printed circuitry techniques are known, including the printing ofmirror heaters for automobiles. Printing electrical conductors onflexible material is known, to replace more expensive wires as discreteconnecting elements between power supplies and electrical consumers.

[0008] A need exists to simplify electrical systems for automobiles,particularly in the relatively compact environments such as exteriormirror housings, while still incorporating a wide variety of electricalfunctions, with differing power demands.

SUMMARY OF THE INVENTION

[0009] The present invention uses the backing layer of a printed circuitfor a mirror heater to print additional circuits functioning as anelectrical buss for distributing electrical power in the mirrorassembly. The actuator can be placed in the mirror housing, and aflexible printed conductor connects the actuator to the printed heatercircuit backing member. A simple three-wire connection can be made fromthe electrical supply source to the actuator, with individualconnections from the various consumers to the printed mirror circuit.

[0010] In one aspect thereof, the present invention provides anelectrical power distribution system for a plurality of electric powerconsumers in an automobile, with a housing, a power center and anelectric power supply source connected to the power center. Theelectrical power supply source includes a flexible substrate and aplurality of circuit traces on the substrate, each having a connectionsite for connecting to one of the consumers.

[0011] In another aspect thereof, the present invention provides anelectric power distribution system, with a power center, an electricpower source electrically connected to the power center and a flexiblepower distributing unit. The distributing unit includes a substratelayer and a conductive layer applied on the substrate layer, theconductive layer including a plurality of traces connected to the powercenter, each trace each having a connecting site for electricallyconnecting to the power consumers.

[0012] In yet another aspect thereof, the present invention provides anautomobile exterior mirror assembly with a mirror pod adapted forconnection to an automobile body, a mirror and plurality of electricalconsumers associated with the mirror disposed in the pod. A power centeris provided in the pod, and is adapted for electrical connection to apower source. A flexible power distributing unit is connected to thepower center. The power distributing center has a flexible substrate anda plurality of electrically conductive traces emanating thereon, and aconnection site on each trace for connecting to consumers.

[0013] An advantage of the present invention is the simplification of anelectrical system for an automobile, by reducing the number of wires andconnectors required.

[0014] Another advantage of the present invention is simplifying theassembly of multi-function automobile exterior rear view mirror systems.

[0015] Still another advantage of the present invention is reducinginstalled costs for automobile exterior mirror units.

[0016] Yet another advantage of the present invention is reducing theweight of mirror units.

[0017] A further advantage of the present invention is eliminatingand/or shortening required wire runs and reducing the number ofconnectors used for automobile exterior mirrors.

[0018] Other features and advantages of the invention will becomeapparent to those skilled in the art upon review of the followingdetailed description, claims and drawings, in which like numerals areused to designate like features.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019]FIG. 1 is an exploded view of an automobile mirror assembly,including a heater element with integrated power feeds in accordancewith the present invention;

[0020]FIG. 2 is an exploded view of a heater element with integratedpower feeds similar to that shown in FIG. 1, but configured for anopposite side of an automobile;

[0021]FIG. 3 is an enlarged view of a connector for use with the heaterelement with integrated power feeds, the connector shown open, without apower feed secured thereto;

[0022]FIG. 4 is an enlarged view of the connector shown in FIG. 3, butillustrating a power feed from the heater element positioned in theconnector for connection thereto; and

[0023]FIG. 5 is an enlarged view of the connector in a closed position,connected to the power feed.

[0024] Before the embodiments of the invention are explained in detail,it is to be understood that the invention is not limited in itsapplication to the details of construction and the arrangements of thecomponents set forth in the following description or illustrated in thedrawings. The invention is capable of other embodiments and of beingpracticed or being carried out in various ways. Also, it is understoodthat the phraseology and terminology used herein are for the purpose ofdescription and should not be regarded as limiting. The use of“including” and “comprising” and variations thereof herein is meant toencompass the items listed thereafter and equivalents thereof as well asadditional items and equivalents thereof.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0025] Referring now more specifically to the drawings, and to FIG. 1 inparticular, an automobile exterior mirror assembly 10 is shown, whichincludes an electrical power distribution system 12 in accordance withthe present invention. It should be understood that use of the presentinvention is not limited to automobile mirrors, and distribution system12 is merely one advantageous configuration in which the presentinvention can be practiced.

[0026] Mirror assembly 10 includes a mirror pod or housing 14 having aleg 16 by which assembly 10 is fastened to an automobile body (notshown), in known manner. The size, style and shape of mirror assembly 10will vary, from one automobile to another. In conjunction therewith, aswill be evident from the description to follow, the size, shape andconfiguration of distribution system 12 will also vary, in partdependent upon the style of mirror assembly 10, but also dependent uponthe number and type of electrically controlled and operated features inmirror assembly 10. Such features, or electrical power consumers 18 mayinclude, for example, a drive mechanism power consumer 18 forcontrolling the angular positioning of the mirror in housing 14. Anotherpower consumer 18 may be a turn signal indicator power consumer 18.Those skilled in the art will recognize that mirror assembly 10 caninclude a variety of other power consumers 18, as discussed previouslyherein.

[0027] In a simple form thereof, the present invention includes acontroller or power center 20 having an electrical connection 22 to thevehicle 12-volt power source. Connection 22, for example, can be asimple three-conductor connection having a plug 24 on a wire 26 that isconnected to the vehicle power source (not shown). A flexible powerdistributing unit 28 (FIG. 2) is electrically connected to power center20, and includes a plurality of connection sites 30 to which variouspower consumers 18 are connected.

[0028] Power distributing unit 28 includes a substrate 32 (see FIG. 2)of sheet-like, preferably, flexible material. Substrate 32 has a mainbody 34 with a plurality of edges 36, and connection sites 30 can beprovided along edges 36. Alternatively, to bring connection sites 30closer to power consumers, substrate 32 can be provided with one or morearms 38 (FIG. 1) radiating therefrom, with connection sites 30positioned along or at ends 40 of arms 38. The flexibility and length ofarms 38 enables the arm to be threaded through and around othercomponents within housing 14, to be connected to a power consumer 18. Todistribute electrical current from power center 20 to connection sites30, for supply to the various electrical consumers 18, substrate 32 isprovided with electrically conductive traces 42, 44 applied thereto.Electrically conductive traces 42, 44 can include an electric buss trace42, and a plurality of distributing traces 44 emanating therefrom. Busstrace 42 is adapted for connection to power center 20, such as via atail 46 of substrate 32 along which buss trace 42 extends. Eachdistributing trace 44 ends at a connection site 30, and is adapted andarranged for connection to a power consumer 18 closely located relativeto power distributing unit 28.

[0029] Different materials are suitable for substrate 32.Advantageously, the material of substrate 32, and particularly arms 38thereof, has sufficient flexibility that it can be bent or otherwisemanipulated as necessary to be routed through and positioned in mirrorhousing 14. Polyester sheet material, such as Mylar is a suitablematerial for substrate 32, although other flexible materials also can beused in accordance with the principles of the present invention.

[0030] Electrically conductive traces 42 and 44 are applied on a firstsurface 48 of substrate 32, to provide electrical paths along substrate32. Traces 42 and 44 can be lines of copper, aluminum, conductiveepoxies, or other conductive materials, as those skilled in the art willrecognize. Traces 42 and 44 can be applied to substrate 32 by any of thewell-known techniques, including, but not limited to, screen printing,pad printing, coating, painting and etching. For simplicity herein, theterms “printing” or “printed” shall be used in reference to theapplication technique, or circuits made thereby. However, it should beunderstood that the terms “printing” or “printed” are not meant to limitthe manner in which traces 42 and 44 can be applied to substrate 32.

[0031] As illustrated in FIG. 2, power distributing unit 28 can beincorporated with existing technology for a mirror heater assembly 50. Aconductor layer or grid 52 is provided on a second surface 54 oppositefirst surface 48 of substrate 32. A positive temperature coefficient(PTC) layer 56 is applied thereover. A diffuser device 57 is shown andcan be used in conjunction with turn signal indicators. Substrate 32 issandwiched between a mirror body 58 (FIG. 1) and a backing plate 60(FIG. 1), and may be secured by a plurality of fastening clips 62 (FIG.1). The construction and operation of self-regulating PTC heaters fordefrosting or de-misting automobile exterior mirrors is well known, andwill not be described in greater detail herein. In the presentinvention, the opposite side of a substrate used for the mirror heateris used for the application of traces 42 and 44. Although described aspart of a PTC heater, the present invention is capable of use in otherheaters, such as, for example, a fixed resistance heater. Alternatively,the principles of the present invention can be used without anassociated mirror heater.

[0032] The various devices, i.e., consumers 18, to be powered may, andlikely will have different electric current requirements. In accordancewith the present invention, a single power level is provided to powercenter 20, and adjustments are made from there on the various printedcircuits. Utilizing a printed circuit as an electrical distributionsystem, the necessary resistors or other current adjusters can beprinted into the circuit, using known techniques. Thus, the electricalcurrent to each consumer can be controlled, as necessary, in anefficient, space-saving and cost effective manner.

[0033] In an automobile environment, such as exterior mirror assembly10, it is necessary to keep the electrical components in a sealedenvironment, to prevent corrosion and the like caused by moisture. Insuch an environment, in the past it has been necessary to include heatsinks in the circuits, to dissipate heat from temperature sensitivecomponents of the circuit. When provided as part of mirror heater 50,and applied directly onto the back surface of the mirror body 58, themass of mirror body 58 acts effectively as a massive heat sink.

[0034] When not included as part of a mirror heater 50, substrate 32 hasonly traces 42 and 44 thereon, without conductor layer 52 and PTC layer56. Advantages are still obtained if substrate 32 is applied to the backof mirror body 58 in that substrate 32 acts as an anti-shatter membranefor mirror 58, and mirror 58 functions as a heat sink.

[0035] During the assembly of mirror assembly 10, substrate 32, withconductive traces 42 and 44, conductor layer 52 and PTC layer 56 thereonis applied to mirror body 58, and secured thereto and to backing plate60 by clips 62. Tail 46 and the electrical conductors thereon, areconnected to a connector 64 (FIG. 1) of power center 20. Connectionsites 30 are connected to the various power consumers 18.

[0036] The various connectors used can be of any suitable construction,including, but not limited to, plug-in type connectors, solderconnectors, crimp connectors, pressure-type connectors, conductive epoxyconnectors, and other types of connecting structures.

[0037]FIGS. 3-5 illustrate an electrical connector 100 that may be usedwith the present invention. In a preferred design, connector 100 is of aone piece, molded construction, but can be of other configurations andconstructions. Connector 100 includes a base 102 and a top 104 connectedto each other by a hinge 106. Top 104 can be moved between an openposition, illustrated in FIGS. 3 and 4, and a closed positionillustrated in FIG. 5. In a preferred design, hinge 106 is a so-calledliving hinge, as those skilled in the art will understand readily;however, hinge 106 can be of constructions other than the living hingeshown. A plurality of electrical contacts 110, 112, 114, 116 is providedin base 102, one contact for each of the electrical traces to whichconnector 100 is to be connected. In the exemplary embodiment of FIGS.3-5, connector 100 includes four electrical contacts 110, 112, 114, 116;however, it should be understood that connector 100 can include more orfewer contacts.

[0038] Each contact 110, 112, 114, 116 is positioned adjacent and inline with a mating recess 120, 122, 124, 126 provided in top 104, intowhich the contact can be inserted. Each contact 110, 112, 114, 116further may include a plurality of contact points, to ensure goodelectrical connection with a trace 42, 44 positioned therewith.

[0039] If used, for example, as a connector with tail 46, connector 100can include a pair of protruding hold down members 132, 134 on base 102.During installation and connection of connector 100 to tail 46, Tail 46is inserted between contacts 110, 112, 114, 116 and hold down members132, 134. Top 104 is lowered onto base 102, with tail 46 properlypositioned therein. Top 104 is secured to base 102 by a pair of snaplocks 140 operatively disposed on opposite sides of connector 100.

[0040] Connector 100 can be sealed or unsealed, and polarized or not.Contact surfaces of connector 100 can be modified, such as byroughening, to ensure more intimate contact and connection.

[0041] Variations and modifications of the foregoing are within thescope of the present invention. It is understood that the inventiondisclosed and defined herein extends to all alternative combinations oftwo or more of the individual features mentioned or evident from thetext and/or drawings. All of these different combinations constitutevarious alternative aspects of the present invention. The embodimentsdescribed herein explain the best modes known for practicing theinvention and will enable others skilled in the art to utilize theinvention. The claims are to be construed to include alternativeembodiments to the extent permitted by the prior art.

[0042] Various features of the invention are set forth in the followingclaims.

What is claimed is:
 1. An electrical power distribution system for aplurality of electric power consumers in an automobile, comprising: apower center; an electrical connection from said power center adaptedfor electrical connection to an electrical power source; and anelectrical power distributing unit electrically connected to said powercenter, and including: a flexible substrate; and a plurality of circuitconductive traces on said substrate, each having a connection site forconnecting to one of the consumers.
 2. The electrical power distributionsystem of claim 1, including a housing comprising an external mirror podcontaining said power center and said distributing unit.
 3. Theelectrical power distribution system of claim 2, wherein each saidconsumer is disposed in said housing.
 4. The electrical powerdistribution system 2, said substrate having a mirror heater thereon. 5.The electrical power distribution system 4, wherein each said consumeris disposed in said housing.
 6. The electric power distribution systemof claim 1, said substrate having a mirror heater thereon.
 7. Theelectric power distribution system of claim 1, said traces applied byone of screen printing, pad printing, coating, painting, and etching. 8.The electrical power distribution system 1, said traces comprising oneof copper, aluminum and conductive epoxy.
 9. The electrical powerdistribution system of claim 1, said substrate including at least oneelongated flexible arm, with at least one connection site at an end ofsaid at least one arm.
 10. The electrical power distribution system ofclaim 1, said substrate including a plurality of edges, with at leastone connection site provided along at least one edge of said pluralityof edges.
 11. An electric power distribution system, comprising: a powercenter; an electrical connection from said power center adapted forelectrical connection to a power source; and a flexible powerdistributing unit including: a substrate having first and secondsurfaces; and a conductive layer applied on one said surface of saidsubstrate, said conductive layer including a plurality of tracesconnected to said power center, each said trace each having a connectingsite for electrically connecting to a power consumer.
 12. The electricpower distribution system of claim 11, said conductive layer applied byone of screen printing, pad printing, coating, painting, and etching.13. The electric power distribution system of claim 11, including a PTCheater applied on said second surface of said substrate.
 14. Theelectric power distribution system of claim 13, said conductive layerapplied by one of screen printing, pad printing, coating, painting andetching.
 15. The electric power distribution system of claim 14, saidconductive layer comprising one of copper, aluminum and conductiveepoxy.
 16. The electric power distribution system of claim 11, saidconductive layer comprising one of copper, aluminum and conductiveepoxy.
 17. An automobile exterior mirror assembly, comprising: a mirrorpod adapted for connection to an automobile body; a mirror body and aplurality of electrical consumers associated with said mirror bodydisposed in said pod; a power center disposed in said pod, said powercenter adapted for electrical connection to a power source; and aflexible power distributing unit connected to said power center, saidpower distributing center having a flexible substrate and a plurality ofelectrically conductive traces disposed thereon, each said traceelectrically connected to said power center; and a connection site oneach said trace for connecting to said consumers.
 18. The automobileexterior mirror assembly of claim 17, said substrate attached to saidmirror body.
 19. The automobile exterior mirror assembly of claim 17,said substrate having a first surface and a second surface, said tracesdisposed on one said surface and a mirror heater disposed on the othersaid surface.
 20. The automobile exterior mirror assembly of claim 19,said traces applied by one of screen printing, pad printing, coating,painting and etching.
 21. The automobile exterior mirror assembly ofclaim 20, said traces comprising one of copper, aluminum and conductiveepoxy.
 22. The automobile exterior mirror assembly of claim 21, saidsubstrate being mylar.
 23. The automobile exterior mirror assembly ofclaim 17, said substrate having a main body and an elongated armextending from said main body; a trace from said main body extendingalong said arm; and a connection site on said arm.
 24. The automobileexterior mirror assembly of claim 17, said substrate having edges, andconnection sites disposed along said edges.